1. Table of contents History Tools Parts manipulation Soldering Soldering iron or station...

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Daniella Grant
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1 1. TABLE OF CONTENTS 1. Table of contents History Tools Parts manipulation Soldering Soldering iron or station Hot-air rework stations Hot Air handguns Heat gun stand Preheaters BGA station Reflow ovens Temperature and power Soldering tips Anatomy of a tip Prolonging tip life Heat gun nozzles Solder Specialty solders Solder paste Paste application Paste dispensers Stencils Stencil printers Surface Mount Technology 3

2 LabWorX 2 Table of contents Squeegees Rework stencils Solder balls Flux Rosin flux No-clean flux Water soluble flux Flux dispensing Flux for lead-free versus leaded process Spattering Voiding Wetting problems Cold solder joints Flux remover Applicators Ultrasonic cleaner Other soldering tools Fume extractor Centralized systems Individual systems Dental picks Xacto knife Solder wick Applicator bottles Soft brush Soldering sponge Surface Mount Technology

3 6. Magnifiers Pocket / inspection magnifier / wearable magnifiers Bench magnifiers with built in light Stereo inspection microscope Computer microscope Vision systems Specialized inspection systems XRAY systems Parts placement Manual placement Advanced manual and semi manual placement systems Automatic placement Parts storage Factory delivered storage Tape and reel Stick Tray Bulk cassette pack Small volume storage Benchtop storage Spring loaded boxes or mousetrap boxes Sample containers Photo Film containers Tackle boxes Jewelers and bead boxes Pill boxes Surface Mount Technology 5

4 LabWorX 2 Table of contents Parts sorters Labeling parts containers ESD and ESD safety What is static electricity ESD protection The necessity of earth ESD safe workstation setup ESD Safe storing of parts Antistatic packaging Dissipative packaging Conductive material Commercial solutions Bench mat ESD straps ESD-safe soldering iron and tools Clothing Ionizers Conductive flooring Antistatic cleaners and surface treatment Other solutions Testers Homegrown solutions Bench mat ESD ground plug ESD safe lab jacket or lab coat A couple of words of caution Surface Mount Technology

5 10. Setting up an efficient workbench The essentials Other things to keep close at hand Taming components Dealing with tape and reel Dealing with loose parts Vacuum pens Poster putty to the rescue Taming the workpiece Helping hands The bench Circuit board assemblies Premade forms Etched boards The home route The professional services Some board terminology Different assembly types SMD Parts on one side only SMD and thru-hole parts on one side only SMD parts top and bottom SMD parts top and bottom + through hole Printed circuit boards Some history PCB material The FR4 misnomer Surface Mount Technology 7

6 LabWorX 2 Table of contents Dielectrical constant Laminate thickness Copper thickness The mechanical process The chemical process Photoplotting Drill file Process evolution Through-hole metallization Etching after metallization Multilayer boards Soldermask Silkscreen Pitfalls with soldermask and silkscreen Surface protection Electrical test Making boards in the home or small lab Toner transfer method Photographic method Pre-coated boards Developer Light source Etching Ferric chloride Persulfates Hydrochloric acid / Hydrogen peroxide Surface Mount Technology

7 13.4. Post processing Reflow soldering Reflow profile Defects Mechanically induced failures Sockets and package adapters Sockets Package adapters SMD components Resistors Footprints Resistor technology Values Value indication Power rating Voltage rating Resistor networks Practical tips for the lab resistor box Capacitors Footprints Ceramic capacitors Capacitor classification Class-I Class II Film capacitors Tantalum capacitors Surface Mount Technology 9

8 LabWorX 2 Table of contents Technology Electrolytic capacitors Construction Electrical behavior Other capacitors ESR: equivalent series resistance ESL: equivalent series inductance inductors Technology Derating PCB inductors Active components Diodes Diode packages Transistors Transistor packages Integrated circuits Small outline packages: SO Power packages SOJ PLCC TSOP / TSSOP QFP / TQFP QFN BGA Flip Chip Surface Mount Technology

9 Naked Die Identifying parts Test tools Test leads Tweezer probes Scope probes Probe holders Smart tweezers Grabbers Testclips SO, PLCC and TQFP contactors Footprint adapters Test and ZIF sockets Soldering techniques Techniques using a standard soldering iron For passive parts, 2 pin and 3 pin parts or parts with few pins For coarse pitch multi-row parts For TQFP or quad style packages For MLF / QFN Techniques involving a hot air station Passive parts Multi-row parts like SO, TSSOP, QFP MLF style Solder paste and stencil techniques Using a micro stencil Full boards Surface Mount Technology 11

10 LabWorX 2 Table of contents Practice makes perfect Project 1: Earth bonding plug Project 2: LED Tester Schematic Workbench setup Preparing the PCB Preparing the component positions Placing the first parts Placing the passive components Diodes and LEDs Finishing touches Applying flux Post processing clean-up Ultrasonic cleaning Project 3: PWM controller for lightbulb Schematic Workbench setup Project 4: Ring light Assembly Positioning the stencil Paste application Inspecting the solder paste deposition Parts placement Soldering Thru-hole parts Project 5: UV Exposure timer Surface Mount Technology

11 Labworx SMD -candidate 7-.pdf 8/5/ :16:01 AM The controller Assembly Workbench setup Board preparation Controller assembly Placing parts Installing the through-hole parts Programming the cpu Final assembly and wrap-up Project 6: Making your own reflow oven from a pizza toaster Schematic Control loop Assembly Firmware Operation Downloadable Material Appendix Project kits Index Surface Mount Technology 13

Weller WR Series Based

Weller WR Series Based Integrated ESD Workstation cum SMD/PTH Rework MulfiFunction Package Allin, Complete ESD Workbench and essential tools/accessories for SMD/PTH Rework reliable & caring since 976 IEWRWPMST3MPK Integrated